Contents

Yamaha YFZ350S Banshee 2004 Owner's Manual PDF

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Summary of Content for Yamaha YFZ350S Banshee 2004 Owner's Manual PDF

YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN

2003032.01 !

This ATV should not be ridden by anyone under 16 years of age.

OWNERS MANUAL

5FK-28199-16

YFZ350S

READ THIS MANUAL CAREFULLY! It contains important safety information.

LIT-11626-17-04 (E)

w

Improper ATV use can result in SEVERE INJURY or DEATH.

qWARNING

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR

NEVER USE ON PUBLIC

ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

NEVER operate: 9 without proper training or instruction. 9 at speeds too fast for your skills or the

conditions. 9 on public roads - a collision can occur with

another vehicle. 9 with a passenger - passengers affect

balance and steering and increase risk of losing control.

ALWAYS: 9 use proper riding techniques to avoid

vehicle overturns on hills and rough terrain and in turns.

9 avoid paved surfaces - pavement may seriously affect handling and control.

EBU00438

LOCATE AND READ OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558)

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EBU13320

INTRODUCTION Congratulations on your purchase of the Yamaha YFZ350. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of crafts- manship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this ATV. This manual includes important safety information. It provides information about spe- cial techniques and skills necessary to ride your ATV. It also includes basic maintenance and inspection procedures.If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE: 8 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND

COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

8 PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV. 8 NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE

TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMATION.

8 THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.

8 THIS ATV IS A HIGH PERFORMANCE ATV FOR OFF-ROAD USE ONLY, FOR SPORT TYPE RECREATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS.

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EBU00801

IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

w Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.

cC A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE: A NOTE provides key information to make procedures easier or clearer.

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EBU00011

IMPORTANT NOTICE

This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this machine on any public street, road or highway. This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this machine.

AFFIX DEALER LABEL HERE

EBU13330

YFZ350S OWNERS MANUAL

2003 by Yamaha Motor Corporation, U.S.A.

1st edition, 2003 All rights reserved.

Any reprinting or unauthorized use without the written permission

of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in Japan. P/N LIT-11626-17-04

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LOCATION OF THE WARNING AND SPECIFICATION LABELS....................1-1

SAFETY INFORMATION......................2-1

DESCRIPTION AND MACHINE IDENTIFICATION .................................3-1

Identification number records............3-2 Key identification number..................3-2 Vehicle identification number ............3-3 Model label ........................................3-3

CONTROL FUNCTIONS ......................4-1 Main switch........................................4-1 Handlebar switches...........................4-2 Throttle lever .....................................4-3 Throttle OverRide System.................4-4 Speed limiter .....................................4-4 Clutch lever .......................................4-6 Front brake lever ...............................4-6 Brake pedal .......................................4-7 Parking brake ....................................4-7 Shift pedal .........................................4-9 Kick starter ........................................4-9 Fuel tank cap...................................4-10 Fuel cock.........................................4-10 Starter (choke).................................4-11

EBU00014

w Indicates a potential hazard that could result in serious injury or death.

CONTENTS

1

2

3

4

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Seat .................................................4-12 Front shock absorber adjustment.....................................4-13

Rear shock absorber adjustment.....................................4-14

PRE-OPERATION CHECKS ................5-1 Front and rear brakes........................5-3 Fuel ...................................................5-5 Engine mixing oil ...............................5-6 Transmission oil ................................5-7 Chain.................................................5-7 Throttle lever .....................................5-8 Fittings and fasteners........................5-8 Lights.................................................5-8 Switches............................................5-8 Tires ..................................................5-9 How to measure tire pressure .........5-10 Tire wear limit ..................................5-11

OPERATION .........................................6-1 Starting a cold engine........................6-1 Starting a warm engine .....................6-3 Warming up .......................................6-3 Shifting ..............................................6-4 To start out and accelerate................6-5 To decelerate.....................................6-6 Engine break-in .................................6-7 Parking ..............................................6-8 Parking on a slope ............................6-9 Accessories and loading .................6-10

Riding Your ATV....................................7-1 Getting to know your ATV..................7-3 Ride with care and good

judgement .......................................7-4 Be careful where you ride ...............7-16 Turning your ATV ............................7-23 Climbing uphill .................................7-25 Riding downhill ................................7-30

5

6

7

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Crossing a slope .............................7-32 Crossing through shallow water ......7-34 Riding over rough terrain.................7-36 Sliding and skidding ........................7-38 What to do if... ................................7-40 What to do... ...................................7-40

PERIODIC MAINTENANCE AND ADJUSTMENT......................................8-1

Owners manual and tool kit ..............8-1 Periodic maintenance/Lubrication .....8-3 Transmission oil ................................8-6 Cooling system..................................8-8 Spark plug inspection......................8-13 Air filter cleaning..............................8-14 Spark arrester cleaning ...................8-17 Carburetor settings..........................8-19 Idle speed adjustment .....................8-26 Throttle lever adjustment.................8-28 Front and rear brake pad inspection ......................................8-29

Brake fluid level check ....................8-30 Brake fluid replacement ..................8-31 Front brake lever free play ..............8-32 Brake pedal height adjustment........8-33 Parking brake adjustment ...............8-34 Adjusting the rear brake light switch ............................................8-36

Clutch adjustment ...........................8-36 Drive chain slack check...................8-37 Drive chain slack adjustment ..........8-37 Lubricating the drive chain ..............8-38 Cable inspection and lubrication .....8-39 Brake and shift pedal/brake and clutch lever lubrication...................8-40

Front upper and lower arm pivot lubrication......................................8-40

Rear arm pivot lubrication ...............8-41 Wheel removal ................................8-42 Wheel installation ............................8-42 Replacing the headlight bulb...........8-43 Headlight beam adjustment ............8-44

8

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Tail/brake light bulb replacement.....8-45 Troubleshooting...............................8-46 Troubleshooting chart......................8-47 No spark..........................................8-50

CLEANING AND STORAGE ................9-1 A. Cleaning........................................9-1 B. Storage .........................................9-3

SPECIFICATIONS..............................10-1

NOISE REGULATION.........................11-1

MAINTENANCE RECORD.................12-1

ATV LIMITED WARRANTY ................13-1

9

10

11

12

13

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Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV.

Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.

1-1

EBU00464

LOCATION OF THE WARNING AND SPECIFICATION LABELS

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w r y

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1-2

q w 1

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5FE-21568-01

qWARNING NEVER ride as a

passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.

5FE-2151H-405FE-21 1H-01

5FK-21696-01

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1-3

r

t y

5FE-21697-01

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2-1

EBU13380

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.

SEVERE INJURY OR DEATH can result if you do not follow these instructions:

8 Read this manual and all labels carefully and follow the operating procedures described. 8 Never operate an ATV without proper training or instruction. Take a Training Course.

Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1-800-887-2887 to find out about the training courses nearest you.

8 Always follow these age recommendation: A child under 16 years old should never operate an ATV with engine size greater than 90cc.

8 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.

8 Never carry a passenger on an ATV.

q SAFETY INFORMATION 2

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2-2

8 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.

8 Never operate an ATV on any public street, road or highway, even a dirt or gravel one. 8 Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You

should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.

8 Never consume alcohol or drugs before or while operating this ATV. 8 Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is

proper for the terrain, visibility and operating conditions, and your experience. 8 Never attempt wheelies, jumps, or other stunts. 8 Always inspect your ATV each time you use it to make sure it is in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in this manual.

8 Always keep both hands on the handlebars and both feet on the footpegs of the ATV during operation.

8 Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

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2-3

8 Never operate on excessively rough, slippery or loose terrain until you have learned and prac- ticed the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

8 Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

8 Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

8 Always follow proper procedures for climbing hills as described in this manual. Check the ter- rain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

8 Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight back- ward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

8 Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique described in this manual on level ground. Avoid crossing the side of a steep hill if possi- ble.

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2-4

8 Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual.

8 Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always fol- low proper procedures when operating over obstacles as described in this manual.

8 Always be careful when skidding or sliding. Learn to safely control skidding or sliding by prac- ticing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of con- trol.

8 Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.

8 Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual.

8 Never modify an ATV through improper installation or use of accessories.

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8 Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributors Safety Hotline at 1-800-852-5344.

2-5

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2-6

POTENTIAL HAZARD

Improper handling of gasoline.

WHAT CAN HAPPEN

Gasoline can catch fire and you could be burned.

HOW TO AVOID THE HAZARD

Always turn off the engine when refuel- ing. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling. Never refuel while smoking, or while in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers.

qWARNING When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the OFF posi- tion. Otherwise, fuel may leak out of the carburetor or fuel tank.

WHAT CAN HAPPEN

Gasoline is poisonous and can cause injuries.

HOW TO AVOID THE HAZARD

If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

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2-7

POTENTIAL HAZARD

Starting or running the engine in a closed area.

WHAT CAN HAPPEN

Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.

HOW TO AVOID THE HAZARD

Always operate your ATV in an area with adequate ventilation.

qWARNING

5FK-9-16-01 3/13/03 11:13 AM Page 17

3-1

1. Tail/brake light 12. Rear shock absorber 2. Seat 13. Spark arrester 3. Kick starter 14. Rear wheel 4. Fuel tank cap 15. Starter (choke) 5. Headlight 16. Shift pedal 6. Brake pedal 17. Clutch lever 7. Rear brake light switch 18. Parking brake 8. Front wheel 19. Main switch 9. Front shock absorber 20. Front brake lever

10. Radiator 21. Throttle lever 11. Fuel cock 22. Handlebar switch

NOTE: The machine you have purchased may differ slightly from those shown in the figures of this manual.

EBU00032

DESCRIPTION AND MACHINE IDENTIFICATION w e r t

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EBU00600

Identification number records Record the key identification number, vehicle identification number and model label informa- tion in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATION NUMBER:

3. MODEL LABEL INFORMATION:

EBU00035

Key identification number The key identification number is stamped on the key as shown in the following illustration. This number can be used for ordering a new key.

1. Key identification number

3-2

1

6

q

3

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EBU00036

Vehicle identification number The vehicle identification number is stamped into the frame.

NOTE: The vehicle identification number is used to identify your machine.

1. Vehicle identification number

EBU00787

Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer.

1. Model label

3-3

q

q

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EBU00039

CONTROL FUNCTIONS

w Indicates a potential hazard that could result in serious injury or death.

EBU09420

Main switch Functions of the respective switch positions are as follows:

ON: The engine can be started only at this position and the headlights and taillight come on when the light switch is on.

OFF: All electrical circuits are switched off. The key can be removed in this position.

4-1

OFF ON

4

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EBU00053

Handlebar switches

1. Light switch LIGHTS 2. Engine stop switch ENG. STOP

EBU11580

Engine stop switch ENG. STOP Make sure that the engine stop switch is in the RUN position before starting the engine. The engine stop switch controls ignition and can be used at all times to stop the engine, espe- cially in an emergency. The engine will not start or run when the engine stop switch is turned to OFF.

EBU13740

Light switch LIGHTS Set the switch to the LO position to switch on the low beam and the taillight. Set the switch to the HI position to switch on the high beam and the taillight. Set the switch to the OFF position to switch off all the lights.

NOTE: The headlights and the taillight can be turned on only when the engine is started.

4-2

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EBU00062

Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.

Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released.

4-3

q

POTENTIAL HAZARD

Malfunction of throttle.

WHAT CAN HAPPEN

The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident.

HOW TO AVOID THE HAZARD

Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you cant find or solve the problem yourself.

qWARNING

1. Throttle lever

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EBU00064

Throttle OverRide System If during operation, the carburetor or the throt- tle cable should malfunction and will not close fully, take your thumb off the throttle lever. The Throttle OverRide System immediately cuts off the ignition.

EBU11590

Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV.

1. Locknut 2. Adjusting screw a. No more than 12 mm (0.47 in)

4-4

POTENTIAL HAZARD

Continuing to ride the ATV after the Throttle OverRide System (T.O.R.S.) has stopped the engine.

WHAT CAN HAPPEN

Riding with a malfunction increases the chance for an accident and injury.

HOW TO AVOID THE HAZARD

Make sure that the cause of the malfunc- tion is corrected before restarting the engine. You should have the ATV inspected by a Yamaha dealer.

qWARNING qa w

5FK-9-16-01 3/13/03 11:13 AM Page 24

4-5

POTENTIAL HAZARD

Improper adjustment of the speed limiter and throttle.

WHAT CAN HAPPEN

The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured.

HOW TO AVOID THE HAZARD

Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 46 mm (0.160.24 in). See page 8-28.

qWARNING

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EBU00068

Clutch lever The clutch lever is located on the left handle- bar. Pull the clutch lever to the handlebar to disen- gage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation.

1. Clutch lever

EBU00070

Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake.

1. Front brake lever

4-6

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q

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EBU00989

Brake pedal The brake pedal is located on the right side of the machine. Push down on the pedal to apply the rear brake.

1. Brake pedal

EBU00080

Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Squeeze the clutch lever while push- ing the button, then push in the lock plate to apply the parking brake. Squeeze the clutch lever to release the parking brake.

NOTE: When the parking brake is used, engine speed is limited to 2,300 r/min. Be sure the parking brake is released before moving the throttle lever. Otherwise, the engine will mis- fire, preventing normal operation.

4-7

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1. Button 2. Lock plate

1. Locked position

4-8

q

POTENTIAL HAZARD

Improper use of the parking brake.

WHAT CAN HAPPEN

The ATV could start moving unexpected- ly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake disc could overheat if you ride the ATV without releasing the park- ing brake. You could lose braking per- formance which could cause an acci- dent. You could also wear out the brakes prematurely.

HOW TO AVOID THE HAZARD

Always set the parking brake before starting the engine. Always be sure you have released the parking brake before you begin to ride.

qWARNING q

w

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EBU00082

Shift pedal This machine is equipped with a constant- mesh 6-speed transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting.

1. Shift pedal N. Neutral

EBU00089

Kick starter Rotate the kick starter away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary-coupled kick starter so the engine can be started in any gear if the clutch is disengaged. However, shifting to neutral before starting is recommended.

1. Kick starter

4-9

6 5 4

1

2 3

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N

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EBU00092

Fuel tank cap Remove the fuel tank cap by turning it coun- terclockwise.

1. Fuel tank cap

EBU00093

Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will

not flow. Always turn the lever to this position when the engine is not run- ning.

ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.

RES: This indicates reserve. If you run out of fuel while riding, turn the lever to this position. THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY. After refuelling, return the fuel cock lever to the ON position.

4-10

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EBU00094

Starter (choke) Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to Starting a cold engine for proper operation. (See page 6-1.)

1. Starter (choke)

4-11

q

a

b

RES

ON

OFF

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EBU00566

Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear.

To install the seat, insert the projection on the front of the seat into the seat holder and push down on the seat at the rear.

NOTE: Make sure that the seat is securely fitted.

1. Projection 2. Holder

4-12

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EBU01104

Front shock absorber adjustment The spring preload can be adjusted to suit the riders weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direction b.

NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment.

4-13

A B C D E

a b

1

2 POTENTIAL HAZARD

Improper shock absorber adjustment.

WHAT CAN HAPPEN

Uneven adjustment can cause poor han- dling and loss of stability, which could lead to an accident.

HOW TO AVOID THE HAZARD

Always adjust the shock absorbers on the left and right side to the same set- ting.

qWARNING

Standard position: C A - Minimum (soft) E - Maximum (hard)

1. Spring preload adjusting ring 2. Position indicator

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EBU01081

Rear shock absorber adjustment The spring preload, rebound damping and compression damping forces of the rear shock absorber can be adjusted to suit the rider s weight and the riding conditions.

Adjust the spring preload as follows. 1. Loosen the locknut. 2. Turn the adjusting nut in direction a to

increase the spring preload and in direc- tion b to decrease the spring preload.

1. Locknut 2. Spring preload adjusting nut

4-14

POTENTIAL HAZARD

This shock absorber contains highly pressurized nitrogen gas.

WHAT CAN HAPPEN

The shock absorber could explode, causing injury or property damage. Cylinder damage could also result in poor handling which could cause an accident.

HOW TO AVOID THE HAZARD

8 Do not tamper with or attempt to open the cylinder assembly.

8 Do not subject the shock absorber to an open flame or other high heat.

qWARNING

8 Do not deform or damage the cylin- der in any way.

8 Do not dispose of a damaged or worn out shock absorber yourself. Take the unit to a Yamaha dealer.

a

b1 2

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NOTE: A special wrench can be obtained at a Yamaha dealer.

3. The length of the spring (installed) changes 1.5 mm (0.06 in) per one turn of the adjusting nut.

4. Tighten the locknut to the specif ied torque.

cC Always tighten the locknut against the adjusting nut and tighten it to the specified torque.

A

Tightening torque: 54 Nm (5.4 m0kgf, 39 ft0lbf)

Installed length: Measurement A

Minimum (hard): 213.5 mm (8.4 in)

Standard: 220.5 mm (8.7 in)

Maximum (soft): 228.5 mm (9.0 in)

A. Spring length 4-15

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4-16

Adjust the rebound damping force as follows. Turn the rebound damping force adjusting screw in direction a to increase the rebound damping force and in direction b to decrease the rebound damping force.

Adjust the compression damping force as fol- lows. Turn the compression damping force adjust- ing screw in direction a to increase the com- pression damping force and in direction b to decrease the compression damping force.

q

b a

From the fully turned-in position

Minimum (soft): 20 clicks out

Standard: 12 clicks out

Maximum (hard): 3 clicks out

1. Compression damping adjuster

1. Rebound damping adjuster

q

b

a

From the fully turned-out position

Minimum (soft): 1 click in

Standard : 11 clicks in

Maximum (hard): 15 clicks in

5FK-9-16-01 3/13/03 11:13 AM Page 36

cC Never turn an adjusting mechanism beyond the minimum and maximum set- tings.

NOTE: Although the total number of clicks of a damp- ing force adjusting mechanism may not exact- ly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjust- ing range. To obtain a precise adjustment, it would be advisable to check the number of clicks of each damping force adjusting mecha- nism and to modify the specifications as nec- essary.

EBU00112

w Indicates a potential hazard that could result in serious injury or death.

POTENTIAL HAZARD

Suspension components become hot during operation.

WHAT CAN HAPPEN

You could be burned.

HOW TO AVOID THE HAZARD

Never touch the compression damping adjuster, rebound damping adjuster or oil reservoir with your bare hand or skin until suspension components have cooled.

qWARNING

4-17

5FK-9-16-01 3/13/03 11:13 AM Page 37

5-1

PRE-OPERATION CHECKS Before using this machine, check the following points:

ITEM ROUTINE PAGE

Brakes 9 Check operation, free play, fluid level and fluid leakage. 5-35-4 9 Fill with DOT 4 brake fluid if necessary. 8-298-33

Clutch 9 Check operation, condition and lever free play. 8-36

Parking brake 9 Check operation, condition and free play. 8-348-35

Fuel 9 Check fuel level. 9 Fill with fuel if necessary.

5-55-6

Transmission oil 9 Check oil level. 9 Fill with oil if necessary.

5-7, 8-68-8

Coolant reservoir 9 Check coolant level. 9 Fill with coolant if necessary.

8-88-12

Drive chain 9 Check chain slack and condition. 9 Adjust if necessary.

5-7, 8-378-40

Throttle 9 Check for proper throttle cable operation. 5-8, 8-28

Wheels and tires 9 Check tire pressure, wear and damage. 5-95-11, 8-42

Fittings and fasteners 9 Check all fittings and fasteners. 5-8

Lights and switches 9 Check for proper operation. 5-8, 8-438-45

5FK-9-16-01 3/13/03 11:13 AM Page 38

5-2

POTENTIAL HAZARD

Failure to inspect the ATV before operat- ing. Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Increases the possibility of an accident or equipment damage.

HOW TO AVOID THE HAZARD

Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and main- tenance procedures and schedules described in the Owners Manual.

qWARNING

5

5FK-9-16-01 3/13/03 11:13 AM Page 39

EBU01092

Front and rear brakes Brake lever and brake pedal 8 Check that there is no free play in the brake

lever. If there is free play, have a Yamaha dealer adjust it.

8 Check for correct brake pedal height. If the pedal height is incorrect, have a Yamaha dealer adjust it.

8 Check the operation of the lever and pedal. They should move smoothly and there should be a firm feeling when the brakes are applied. If not, have a Yamaha dealer inspect the brake system.

Brake fluid level Check the brake fluid level. Add fluid if neces- sary. (See pages 8-308-31.)

Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs. Apply the brakes firmly for one minute. If there is any leakage, the brake system should be inspected by a Yamaha dealer.

Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking perfor- mance, inspect the brake pads for wear. (See page 8-29.)

5-3

Recommended brake fluid: DOT 4

5FK-9-16-01 3/13/03 11:13 AM Page 40

5-4

POTENTIAL HAZARD

Riding with improperly operating brakes.

WHAT CAN HAPPEN

You could lose braking ability, which could lead to an accident.

HOW TO AVOID THE HAZARD

Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have a Yamaha dealer check for the cause.

qWARNING

5FK-9-16-01 3/13/03 11:13 AM Page 41

EBU13420

Fuel Make sure there is sufficient gasoline in the tank.

1. Filler tube 2. Fuel level

Your Yamaha engine has been designed to use premium unleaded gasoline with a pump octane number ([R+M]/2) of 90 or higher, or research octane number of 95 or higher. If knocking or pinging occurs, use a different brand of gasoline. Unleaded fuel will give you longer spark plug life and reduced mainte- nance cost. If unleaded gasoline is not avail- able, then leaded premium gasoline can be used.

Gasohol There are two types of gasohol; gasohol con- taining ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recom- mended by Yamaha because it may cause fuel system damage or vehicle performance problems.

5-5

Recommended fuel: PREMIUM UNLEADED FUEL

Fuel tank capacity: Total:

12 L (2.6 Imp gal, 3.2 US gal) Reserve:

2.5 L (0.5 Imp gal, 0.7 US gal)

q w

5FK-9-16-01 3/13/03 11:13 AM Page 42

EBU00132

Engine mixing oil

If Yamalube R oil is not available, select an oil from the following list.

cC Never mix two types of oil in the same batch. Always use the same type of oil to ensure maximum engine performance.

5-6

POTENTIAL HAZARD

Improper care when refueling.

WHAT CAN HAPPEN

Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun.

HOW TO AVOID THE HAZARD

Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely. Do not refuel right after the engine has been running and is still very hot.

qWARNING

Recommended oil: Yamalube R (Yamalube Racing 2-cycle oil) Mixing ratio: 24:1

Recommended oil Mixing ratio

Castrol R30 A545 20:1 A747

5FK-9-16-01 3/13/03 11:13 AM Page 43

EBU12890

Transmission oil Make sure the transmission oil is at the speci- fied level. Add oil as necessary. (See pages 8-68-8.)

cC 8 In order to prevent clutch slippage

(since the transmission oil also lubri- cates the clutch), do not mix any chem- ical additives. Do not use oils with a diesel specification of CD or oils of a higher quality than specified. In addi- tion, do not use oils labeled ENERGY CONSERVING II or higher.

8 Make sure that no foreign material enters the crankcase.

EBU00498

Chain Check the general condition of the chain and check the chain slack before every ride. Lubricate and adjust the chain as necessary. (See pages 8-378-40 for details.)

5-7

Recommended oil: Yamalube 4 (10W30) or SAE 10W30

Recommended oil classification: API Service SE, SF, SG type or higher

Oil quantity: Total amount:

1.7 L (1.5 Imp qt, 1.8 US qt) Periodic oil change:

1.5 L (1.3 Imp qt, 1.6 US qt)

5FK-9-16-01 3/13/03 11:13 AM Page 44

5-8

EBU01083

Throttle lever Check to see that the throttle lever operates correctly. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer repair as necessary for proper operation.

EBU11620

Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque.

EBU10030

Lights Check the headlights and tail/brake light to make sure they are in working condition. Repair as necessary for proper operation.

EBU11700

Switches Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation.

5FK-9-16-01 3/13/03 11:13 AM Page 45

5-9

EBU00157

Tires

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or uneven tire pressure.

WHAT CAN HAPPEN

Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident.

HOW TO AVOID THE HAZARD

1. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. Other tire combina- tions are not recommended.

2. The tires should be set to the recom- mended pressure:

qWARNING

Manufacturer Size Type

Front DUNLOP AT21 710 KT851A

Rear DUNLOP AT20 109 KT877

9 Recommended tire pressure Front 30 kPa (0.30 kgf/cm2, 4.4 psi) Rear 30 kPa (0.30 kgf/cm2, 4.4 psi) 9 Check and adjust tire pressures

when the tires are cold. 9 Tire pressures must be equal on

both sides. 3. Tire pressure below the minimum

specified could cause the tire to dis- lodge from the rim under severe rid- ing conditions. The following are minimums: Front 27 kPa (0.27 kgf/cm2, 3.9 psi) Rear 27 kPa (0.27 kgf/cm2, 3.9 psi)

4. Use no more than the following pres- sures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst.

5FK-9-16-01 3/13/03 11:13 AM Page 46

5-10

EBU00159

How to measure tire pressure Use the low-pressure tire gauge.

NOTE: The low-pressure tire gauge is included as standard equipment. Make two measure- ments of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.

Set pressure with tires cold. Set tire pressures to the following specifica- tions:

1. Low-pressure tire gauge

q

30 kPa (0.30 kgf/cm2,

4.4 psi)

27 kPa (0.27 kgf/cm2,

3.9 psi)

33 kPa (0.33 kgf/cm2,

4.7 psi)

30 kPa (0.30 kgf/cm2,

4.4 psi)

27 kPa (0.27 kgf/cm2,

3.9 psi)

33 kPa (0.33 kgf/cm2,

4.7 psi)

Front

Rear

Recommended pressure

Minimum Maximum

5FK-9-16-01 3/13/03 11:13 AM Page 47

EBU00160

Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire.

5-11

a

a. Tire wear limit

5FK-9-16-01 3/13/03 11:13 AM Page 48

EBU00161

OPERATION

w Indicates a potential hazard that could result in serious injury or death.

EBU00511

Starting a cold engine

1. Set the parking brake. 2. Turn the fuel cock to ON. 3. Turn the main switch to ON and the

engine stop switch to RUN. 4. Shift the transmission into neutral. 5. Use the starter (choke) in reference to the

figure: 6-1

POTENTIAL HAZARD

Operating ATV without being familiar with all controls.

WHAT CAN HAPPEN

Loss of control, which could cause an accident or injury.

HOW TO AVOID THE HAZARD

Read the Owners Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer.

qWARNING

POTENTIAL HAZARD

Freezing control cables in cold weather.

WHAT CAN HAPPEN

You could be unable to control the ATV, which could lead to an accident or colli- sion.

HOW TO AVOID THE HAZARD

When riding in cold weather, always make sure all control cables work smoothly before you begin riding.

qWARNING

6

5FK-9-16-01 3/13/03 11:13 AM Page 49

Position 1: Cold engine start- ambient temperature below 5C (40F).

Position 2: Cold engine start- ambient temperature at 0C (30F)30C (90F) and warming up position.

Position 3: Cold engine start- ambient temperature above 25C (80F) and warm engine start position.

6. Completely close the throttle lever and start the engine by kicking the kick starter.

7. If the engine is started with the starter (choke) in position 1, the starter (choke) should be returned to position 2 to warm up the engine. If the engine is started with the starter (choke) in position 2, keep the starter (choke) in this position to warm up the engine.

8. Continue warming up the engine until it idles smoothly and return the starter (choke) to position 3 before riding.

cC See the Engine break-in section prior to operating engine for the first time.

6-2

eq

0

30

10 20 30

50 70 90 F

C AMBIENT TEMP. / STARTER (CHOKE) POSITION

w

eq w

a

1. Fully open 2. Half open 3. Closed a. Starter (choke)

5FK-9-16-01 3/13/03 11:13 AM Page 50

EBU00180

Starting a warm engine To start a warm engine, refer to the Starting a cold engine section. The starter (choke) should not be used. The throttle should be opened slightly.

EBU00538

Warming up To get maximum engine life, always warm up the engine before starting off. Never acceler- ate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally with the starter (choke) turned off.

NOTE: When the parking brake is used, engine speed is limited to 2,300 r/min. Be sure the parking brake is released before moving the throttle lever. Otherwise, the engine will mis- fire, preventing normal operation.

6-3

5FK-9-16-01 3/13/03 11:13 AM Page 51

EBU00198

Shifting This model has a 6-speed forward transmis- sion. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, return the throttle lever to its original position, apply the clutch and repeatedly depress the shift pedal until it stops. When it stops, it will be in first gear. Raise the pedal slightly to neutral.

cC 1. Do not coast for long periods with the

engine off, and do not tow the machine a long distance. Even in neutral posi- tion, the transmission is only properly lubricated when the engine is running. Inadequate lubrication may cause dam- age.

2. Always use the clutch when changing gears. The engine, transmission and drive train are not designed to with- stand the shock of forced shifting and can be damaged by shifting without the clutch.

6-4

6 5 4

1

2 3

N

N. Neutral

5FK-9-16-01 3/13/03 11:13 AM Page 52

EBU00203

To start out and accelerate 1. Release the throttle lever.

cC Always close the throttle while shifting gears. Otherwise, damage to the engine and drive train may result.

2. Pull the clutch lever to disengage the clutch.

3. Shift into first gear. 4. Open the throttle gradually and at the

same time, release the clutch lever slowly. 5. Once the machine has attained adequate

speed, release the throttle, and at the same time, quickly pull in the clutch lever.

6. Shift into second gear. (be careful not to shift into neutral)

7. Open the throttle part way and gradually release the clutch lever.

8. Follow the same procedure when shifting to the next higher gear.

6-5

POTENTIAL HAZARD

Opening the throttle abruptly or releas- ing the clutch lever too quickly.

WHAT CAN HAPPEN

The machine could wheelie. This would increase the chance of an accident, including overturn.

HOW TO AVOID THE HAZARD

Open the throttle gradually. Release the clutch lever gradually.

qWARNING

5FK-9-16-01 3/13/03 11:13 AM Page 53

EBU00207

To decelerate When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing con- trol and increasing the possibility of an acci- dent.

6-6

POTENTIAL HAZARD

Engaging a lower gear when the engine speed is too high.

WHAT CAN HAPPEN

The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage.

HOW TO AVOID THE HAZARD

Make sure the engine has sufficiently slowed before shifting to a lower gear.

qWARNING

5FK-9-16-01 3/13/03 11:13 AM Page 54

6-7

EBU00209

Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full throttle oper- ation or any condition which might result in excessive engine heating must be avoided. However, momentary (23 seconds maxi- mum) full throttle operation under load does not harm the engine. Each full throttle acceleration sequence should be followed with a substantial rest peri- od for the engine by cruising at lower r/min so the engine can rid itself of the temporary build up of heat.

If any abnormality is noticed during this peri- od, consult a Yamaha dealer. 1. 010 hours:

Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of opera- tion. Vary the speed of the machine from time to time. Do not operate it at one set throttle position.

2. 1020 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely through the gears but do not use full throttle at any time.

3. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally.

5FK-9-16-01 3/13/03 11:14 AM Page 55

EBU00212

Parking When parking, stop the engine and shift into low gear. Turn the fuel cock to OFF and apply the parking brake.

1. Locked position

6-8

q

5FK-9-16-01 3/13/03 11:14 AM Page 56

EBU00992

Parking on a slope 1. Bring the machine to a stop by applying the brakes in low gear.

2. Stop the engine and release the clutch lever.

3. With the front and rear brakes applied, apply the parking brake and slowly release the brake pedal.

6-9

POTENTIAL HAZARD

Parking on a hill or other incline.

WHAT CAN HAPPEN

The ATV could roll out of control, increasing the chance of an accident.

HOW TO AVOID THE HAZARD

Avoid parking on hills or other inclines. If you must park on an incline, put the machine in low gear, apply the parking brake, and block the front and rear wheels with rocks or other objects. Do not park the ATV at all on hills that are so steep you could not walk up them easily.

qWARNING

5FK-9-16-01 3/13/03 11:14 AM Page 57

EBU00221

Accessories and loading

EBU00222

Accessories Accessories can affect the handling and con- trol of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. 8 Choose only accessories designed for your

ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other acces- sories may also be available on the market. However, it is not possible for Yamaha to test all non-Yamaha accessories, nor have any control over the quality or suitability of them. Choose a genuine Yamaha accesso- ry, or one that is equivalent in design and quality.

8 Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV.

8 Do not mount an accessory where it could interfere with your ability to control the ATV. Examples include (but are not limited to) a heavy or bulky object attached to the han- dlebars which could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view.

8 Use extra caution when riding an ATV with accessories. The ATV may handle different- ly than it does without accessories.

6-10

5FK-9-16-01 3/13/03 11:14 AM Page 58

EBU00584

Loading As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. Keep the following points in mind: 8 Never exceed the weight limits shown. An

overloaded ATV can be unstable.

8 Load cargo on the carriers as close to the center of the vehicle as possible. Put cargo at the rear of the front carrier and at the front of the rear carrier. Center the load from side to side.

8 Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an acci- dent.

8 Make sure the load does not interfere with controls or your ability to see where you are going.

8 Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trailer.

8 Allow more braking distance. A heavier vehicle takes longer to stop.

8 Avoid making sharp turns unless at very slow speeds.

8 Avoid hills and rough terrain. Choose ter- rain carefully. Added weight affects the sta- bility and handling of the ATV.

6-11

MAXIMUM LOADING LIMIT Vehicle loading limit (total weight of cargo, rider and accessories):

100 kg (220 lb)

5FK-9-16-01 3/13/03 11:14 AM Page 59

POTENTIAL HAZARD

Overloading this ATV or carrying or tow- ing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in vehicle han- dling which could lead to an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.

qWARNING

EBU13551

w Indicates a potential hazard that could result in serious injury or death.

6-12

5FK-9-16-01 3/13/03 11:14 AM Page 60

17-1

Riding Your ATV

OK OK

OK

OK

7-1

7

5FK-9-16-02 3/11/03 1:08 PM Page 1

7-2

5FK-9-16-02 3/11/03 1:08 PM Page 2

7-3

GETTING TO KNOW YOUR ATV This ATV is intended for recreational use by experienced operators only. Even though you are an experienced operator of all other all terrain vehicles or motorcycles, riding the ATV requires special skills acquired through practice. Take your time to fully learn techniques before attempting more difficult maneuvers.

Riding your new ATV can be a very enjoyable activity, providing you with hours of pleasure. But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely. Before you begin to ride, be sure you have read this Owners Manual completely and understand

the operation of the controls. Pay particular attention to the safety information on pages 2-12-7. Please also read all caution and

warning labels on your ATV.

w Indicates a potential hazard that could result in serious injury or death.

5FK-9-16-02 3/11/03 1:08 PM Page 3

7-4

RIDE WITH CARE AND GOOD JUDGE- MENT

Get training if you are inexperienced. Beginners should get training from a certified instructor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum performance until you are totally familiar with the ATVs han- dling and performance characteristics.

Riding your ATV requires skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneu- vers.

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in dif- ferent situations and on different types of terrain

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating tech- niques described in this Owners Manual. For more information about the training course, contact an authorized ATV deal- er or call 1-800-887-2887.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 4

7-5

Not recommended for children under 16 years of age.

POTENTIAL HAZARD

Failure to follow the age recommenda- tions for this ATV.

WHAT CAN HAPPEN

Use by children of ATVs that are not rec- ommended for their age can lead to severe injury or death of the child.

HOW TO AVOID THE HAZARD

A child under 16 should never operate an ATV with engine size greater than 90cc.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 5

7-6

This ATV is designed to carry operator only - passengers prohibited.

POTENTIAL HAZARD

Carrying a passenger on this ATV.

WHAT CAN HAPPEN

Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger.

HOW TO AVOID THE HAZARD

Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 6

Apparel

7-7

POTENTIAL HAZARD

Operating this ATV without wearing an approved motorcycle helmet, eye pro- tection and protective clothing.

WHAT CAN HAPPEN

Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.

Operating without protective clothing increases your chances of severe injury in the event of an accident.

HOW TO AVOID THE HAZARD

Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield)

gloves boots long-sleeved shirt or jacket long pants

qWARNING

Gloves

Goggles

Boots

Helmet

Protective clothing

5FK-9-16-02 3/11/03 1:08 PM Page 7

7-8

Do not operate after consuming alcohol or drugs. Operators performance capability is reduced by the influence of alcohol or drugs.

POTENTIAL HAZARD

Operating this ATV after consuming alcohol or drugs.

WHAT CAN HAPPEN

Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and percep- tion. Could result in an accident.

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or while driving this ATV.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 8

7-9

Pre-operation checks Always perform the pre-operation checks list- ed on page 5-1 before riding for safety and proper care of the ATV.

POTENTIAL HAZARD

Failure to inspect the ATV before operat- ing. Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Increases the possibility of an accident or equipment damage.

HOW TO AVOID THE HAZARD

Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owners Manual.

qWARNING

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or uneven tire pres- sure.

WHAT CAN HAPPEN

Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an acci- dent.

HOW TO AVOID THE HAZARD

Always use the size and type tires speci- fied in the Owners Manual for this vehi- cle on pages 5-9. Always maintain proper tire pressure as described in the Owners Manual on page 5-10.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 9

w Indicates a potential hazard that could result in serious injury or death.

Do not operate at speeds too fast for your skills or the conditions.

Speed limiter For riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits the power and top speed of the ATV. Turning the adjusting screw in decreases the top speed, and turning it out increases the top speed. (See page 4-4 for details.)

7-10

POTENTIAL HAZARD

Operating this ATV at speeds too fast for your skills or the conditions.

WHAT CAN HAPPEN

Increases your chances of losing con- trol of the ATV, which can result in an accident.

HOW TO AVOID THE HAZARD

Always go at a speed that is proper for the terrain, visibility and operating con- ditions, and your experience.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 10

7-11

Loading and accessories As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATVs handling may be adversely affected. Reduce your speed when adding additional loads.

MAXIMUM LOADING LIMIT Vehicle loading limit (total weight of rider, cargo and accessories):

100 kg (220 lb)

POTENTIAL HAZARD

Overloading this ATV or carrying or tow- ing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in vehicle han- dling which could lead to an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in your Owners Manual for carrying cargo or pulling a trailer.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 11

7-12

During operation Always keep your feet on the footboards dur- ing operation. Otherwise your feet may con- tact the rear wheels.

POTENTIAL HAZARD

Removing hands from handlebars or feet from footboards during operation.

WHAT CAN HAPPEN

Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.

HOW TO AVOID THE HAZARD

Always keep both hands on the handle- bars and both feet on the footboards of your ATV during operation.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 12

Avoid wheelies and jumping. You may lose control of the ATV or overturn.

7-13

POTENTIAL HAZARD

Attempting wheelies, jumps, and other stunts.

WHAT CAN HAPPEN

Increases the chance of an accident, including an overturn.

HOW TO AVOID THE HAZARD

Never attempt stunts, such as wheelies or jumps. Dont try to show off.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 13

7-14

Modifications

POTENTIAL HAZARD

Operating this ATV with improper modi- fications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ- ations could lead to an accident.

HOW TO AVOID THE HAZARD

Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an autho- rized ATV dealer.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 14

Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it.

7-15

POTENTIAL HAZARD

Hot exhaust system.

WHAT CAN HAPPEN

Dry grass or brush or other combustible material accumulated around the engine area could catch fire. Someone touching the exhaust system during or after oper- ation could be burned.

qWARNING

HOW TO AVOID THE HAZARD

Do not operate, idle, or park the ATV in dry grass or other dry ground cover. Keep the engine area free of dry grass, brush, or other combustible material. Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it.

5FK-9-16-02 3/11/03 1:08 PM Page 15

7-16

BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control.

POTENTIAL HAZARD

Operating this ATV on paved surfaces.

WHAT CAN HAPPEN

ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of con- trol.

HOW TO AVOID THE HAZARD

Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 16

7-17

Do not ride on any public road, street, or high- way. Riding on public roads can result in collisions with other vehicles.

POTENTIAL HAZARD

Operating this ATV on public streets, roads or highways.

WHAT CAN HAPPEN

You can collide with another vehicle.

HOW TO AVOID THE HAZARD

Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and high- ways.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 17

Know the terrain where you ride. Ride cau- tiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset.

7-18

POTENTIAL HAZARD

Failure to use extra care when operating this ATV on unfamiliar terrain.

WHAT CAN HAPPEN

You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control.

HOW TO AVOID THE HAZARD

Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain con- ditions when operating the ATV.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 18

7-19

POTENTIAL HAZARD

Failure to use extra care when operating on excessively rough, slippery or loose terrain.

WHAT CAN HAPPEN

Could cause loss of traction or vehicle control, which could result in an acci- dent, including an overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills neces- sary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 19

7-20

When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch.

Do not ride in areas posted no trespassing. Do not ride on private property without getting permission.

POTENTIAL HAZARD

Operating in areas where you might not be seen by other off-road vehicles.

qWARNING

WHAT CAN HAPPEN

You could be in a collision. You could be injured.

HOW TO AVOID THE HAZARD

Always mount a caution flag on the ATV to make you more visible. Watch careful- ly for other vehicles.

5FK-9-16-02 3/11/03 1:08 PM Page 20

Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Always avoid riding on paved surfaces: the ATV is designed for off-road use only, and handling maneuvers are more difficult to per- form on pavement.

Set the parking brake and follow the instruc- tions on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your ATV. As you get on the ATV, be sure not to accidentally move the shift pedal. Remember that the engine and exhaust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components.

With the engine idling, pull the clutch lever to disengage the clutch and shift into 1st gear, and then release the parking brake. Open the throttle gradually, and at the same time, release the clutch lever slowly. Once the ATV has attained adequate speed, release the throttle lever and at the same time, quickly pull in the clutch lever and shift into 2nd gear. Open the throttle part way and gradually release the clutch. Use this same procedure as you move into the higher gears. Be sure to coordinate the use of the throttle and shift pedal properly. If the throttle is applied too abruptly or if the throttle is not released during shifting, or if the shift pedal is not released before applying the throttle, the front wheels may lift off the ground resulting in a loss of directional control. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV.

7-21

5FK-9-16-02 3/11/03 1:08 PM Page 21

7-22

cC Do not shift gears without releasing the throttle. Damage to the engine or drive train may occur.

When slowing down or stopping, release the throttle and apply the brakes smoothly and

evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing con- trol and increasing the possibility of an acci- dent.

POTENTIAL HAZARD

Opening the throttle abruptly or releas- ing the clutch lever too quickly.

WHAT CAN HAPPEN

The ATV could wheelie. This would increase the chance of an accident, including overturn.

HOW TO AVOID THE HAZARD

Open the throttle gradually. Release the clutch lever gradually.

qWARNING

POTENTIAL HAZARD

Engaging a lower gear when the engine speed is too high.

WHAT CAN HAPPEN

The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage.

HOW TO AVOID THE HAZARD

Make sure the engine has sufficiently slowed before shifting to a lower gear.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 22

7-23

TURNING YOUR ATV To achieve maximum traction while riding off- road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easi- ly. It is essential that this skill be learned first at low speed.

As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the footboard to the outside of the turn (opposite your desired direction) and lean your upper body into the turn. Use the throttle to maintain an even speed through the turn. This maneu- ver will let the wheel on the inside of the turn slip slightly, allowing the ATV to make the turn properly.

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

The ATV could go out of control, caus- ing a collision or overturn.

qWARNING

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in this Owners Manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions.

5FK-9-16-02 3/11/03 1:08 PM Page 23

7-24

This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesnt turn, come to a stop and then practice the procedure again. If the riding sur- face is slippery or loose, it may help to posi- tion more of your weight over the front wheels by moving forward on the seat.

Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves.

Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over. Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your ATV.

Lean towards inside of turn. Support your

weight on the outer footboard.

5FK-9-16-02 3/11/03 1:08 PM Page 24

7-25

CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose sur- faces, or obstacles that might cause you to lose control.

It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars.

POTENTIAL HAZARD

Operating on excessively steep hills.

WHAT CAN HAPPEN

The vehicle can overturn more easily on extremely steep hills than on level sur- faces or small hills.

qWARNING

HOW TO AVOID THE HAZARD

Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempt- ing large hills.

5FK-9-16-02 3/11/03 1:08 PM Page 25

7-26

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for climbing hills as described in this Owners Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slip- pery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backwards.

qWARNING

OK

Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

5FK-9-16-02 3/11/03 1:08 PM Page 26

7-27

If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill.

POTENTIAL HAZARD

Improperly crossing hills or turning on hills.

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.

qWARNING

When crossing the side of a hill:

Always follow proper procedures as described in the Owners Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

OK

5FK-9-16-02 3/11/03 1:08 PM Page 27

7-28

If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dis- mount the ATV on the uphill side. Physically turn the ATV around and then descend the hill.

If you start to roll backwards, DO NOT use the rear brake to stop or try to put the ATV in gear. The ATV could easily tip over back- wards. Instead, apply the front brake gradual- ly, or dismount the ATV immediately on the uphill side.

POTENTIAL HAZARD

Stalling, rolling backwards or improper- ly dismounting while climbing a hill.

WHAT CAN HAPPEN

Could result in the ATV overturning.

HOW TO AVOID THE HAZARD

Use proper gear and maintain steady speed when climbing a hill.

If you lose all forward speed:

Keep weight uphill. Apply the brakes. Lock the parking brake, after you are stopped.

If you begin rolling backwards:

Keep weight uphill. Never apply the rear brake while rolling backwards. Apply the front brake.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 28

7-29

When fully stopped, apply the rear brake as well, and then lock the park- ing brake.

Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the pro- cedure described in the Owner s Manual.

5FK-9-16-02 3/11/03 1:08 PM Page 29

RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the engine compression to do most of the braking for you. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces. Braking ability and trac- tion may be adversely affected by these sur- faces. Improper braking may also cause a loss of traction.

Whenever possible, ride your ATV straight downhill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear

POTENTIAL HAZARD

Going down a hill improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for going down hills as described in this Owners Manual. Note: a special tech- nique is required when braking as you go down a hill. Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

qWARNING

7-30

5FK-9-16-02 3/11/03 1:08 PM Page 30

7-31

OK

5FK-9-16-02 3/11/03 1:08 PM Page 31

7-32

CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance.

As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the steering when riding on loose sur- faces by pointing the front wheels slightly uphill. When riding on slopes be sure not to make sharp turns either up or down hill.

If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you wish to travel.

POTENTIAL HAZARD

Improperly crossing hills or turning on hills.

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.

When crossing the side of a hill:

Always follow proper procedures as described in the Owners Manual.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 32

7-33

Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

OK

5FK-9-16-02 3/11/03 1:08 PM Page 33

7-34

CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and carefully.

POTENTIAL HAZARD

Operating this ATV through deep or fast flowing water.

WHAT CAN HAPPEN

Tires may float, causing loss of traction and loss of control, which could lead to an accident.

qWARNING

HOW TO AVOID THE HAZARD

Never operate this ATV in fast flowing water or in water deeper than that speci- fied in your Owners Manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.

5FK-9-16-02 3/11/03 1:08 PM Page 34

7-35

Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability.

cC After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the ATV in fresh water if it has been operated in salt water or muddy con- ditions.

1. Check hose

q

5FK-9-16-02 3/11/03 1:08 PM Page 35

7-36

RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result.

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Could cause loss of control or a colli- sion. Could cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles. Never attempt to ride over large obsta- cles, such as large rocks or fallen trees. When you go over obstacles, always fol- low proper procedures as described in the Owners Manual.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 36

7-37

5FK-9-16-02 3/11/03 1:08 PM Page 37

7-38

SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, position- ing your weight over the front wheels will sometimes help.

If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide.

5FK-9-16-02 3/11/03 1:08 PM Page 38

7-39

With practice, over a period of time, skill at controlled sliding can be developed. The ter- rain should be chosen carefully before attempting such maneuvers, since both stabil- ity and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost.

POTENTIAL HAZARD

Skidding or sliding improperly.

WHAT CAN HAPPEN

You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Learn to safely control skidding or slid- ing by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

qWARNING

5FK-9-16-02 3/11/03 1:08 PM Page 39

WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely.

WHAT TO DO ...

8 If your ATV doesnt turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See pages 7-237-24.)

8 If your ATV begins to tip while turning: Lean more into the turn to regain balance. If necessary, gradually let off the throttle and/or steer to the outside of the turn. (See pages 7-2324.)

8 If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See pages 7-387-39.)

8 If your ATV cant make it up a hill you are trying to climb: Turn the ATV around if you still have for- ward speed. If not, stop, dismount on the uphill side of the ATV and physically turn the ATV around. If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE - the ATV may tip over on top of you. Dismount the ATV on the uphill side. (See pages 7-257-29.)

7-40

5FK-9-16-02 3/11/03 1:08 PM Page 40

8 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to main- tain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you dis- cover that the ATV is going to tip over, dis- mount on the uphil l side. (See pages 7-327-33.)

8 If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See pages 7-347-35.)

w Indicates a potential hazard that could result in serious injury or death.

7-41

5FK-9-16-03 3/13/03 8:39 AM Page 1

EBU00515

PERIODIC MAINTENANCE AND ADJUSTMENT

Periodic inspection, adjustment and lubrica- tion will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages.

EBU12210

Owners manual and tool kit You are recommended to put this owners man- ual and low-pressure tire gauge in the vinyl bag and always carry them along with the owners tool kit under the seat.

1. Owners manual 2. Low-pressure tire gauge 3. Owners tool kit8-1

q

w

e

POTENTIAL HAZARD

Servicing an engine while it is running.

WHAT CAN HAPPEN

Moving parts can catch clothing or parts of the body, causing injury. Electrical components can cause shocks or can start fires.

qWARNING

HOW TO AVOID THE HAZARD

Turn off the engine when performing maintenance unless otherwise specified. Have a Yamaha dealer perform service if you are not familiar with machine service.

5FK-9-16-03 3/13/03 8:39 AM Page 2

The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the owners tool kit are suffi- cient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts.

NOTE: If you do not have a torque wrench available during a service operation requiring one, take your machine to a Yamaha dealer to check the torque settings and adjust them as necessary.

8-2

POTENTIAL HAZARD

Operating this ATV with improper modi- fications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ- ations could lead to an accident.

HOW TO AVOID THE HAZARD

Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an autho- rized Yamaha ATV dealer.

qWARNING

8

5FK-9-16-03 3/13/03 8:39 AM Page 3

EBU00261

PERIODIC MAINTENANCE/LUBRICATION

8-3

INITIAL EVERY

ITEM ROUTINE 1 3 6 6 1 month months months months year

Transmission 9 Replace oil. 2 2 2 2

9 Check coolant leakage. Cooling system 9 Repair if necessary. 2 2 2 2 2

9 Replace coolant every 24 months.

9 Check condition. Spark plug 9 Adjust gap and clean. 2 2 2 2 2

9 Replace if necessary.

Air filter element 9 Clean. Every 2040 hours. 9 Replace if necessary. (More often in wet or dusty areas)

* Carburetor 9 Check idle speed / starter operation. 2 2 2 2

9 Adjust if necessary.

* Crankcase breather 9 Check breather hose for cracks or damage. 2 2 2

system 9 Replace if necessary. 9 Check for leakage.

* Exhaust system 9 Retighten if necessary. 2 2 2 9 Replace gasket(s) if necessary.

Spark arrester 9 Clean. 2 2 2

* Fuel line 9 Check fuel hose for cracks or damage. 2 2 2

9 Replace if necessary.

Throttle operation 9 Inspect and adjust free play if necessary. 2 2 2 2 2

* Front and rear 9 Check operation/fluid leakage/See NOTE Page 8-5. 2 2 2 2 2brake operation 9 Correct if necessary.

* Front and rear 9 Check pad wear. 2 2 2brake pads 9 Replace if necessary.

5FK-9-16-03 3/13/03 8:39 AM Page 4

* It is recommended that these items be serviced by a Yamaha dealer. ** Lithium soap base grease

8-4

INITIAL EVERY

ITEM ROUTINE 1 3 6 6 1 month months months months year

* Clutch 9 Inspect free play and operation. 2 2 2 2

9 Replace if necessary. 9 Check chain slack/alignment.

Drive chain 9 Adjust if necessary. 2 2 2 2

9 Clean and lube. 9 Replace if necessary.

*Drive chain guard and rollers 9 Check wear and replace if necessary. 2 2 2

* Steering system 9 Inspect free play, clean and lubricate 2 2 2 2 2

*Front and rear 9 Inspect and lubricate.** 2 2 2 2 2suspension

Tires 9 Inspect air pressure, wheel runout, and tire wear. 2 2 2 2 2

*Wheels 9 Inspect bearings. 2 2 2 2 2

9 Replace bearings if necessary.

Throttle, control cable 9 Check routing and connection. 2 2 2 2 2

9 Lubricate.

Outside nuts and bolts 9 Retighten. 2 2 2 2 2

Frame 9 Clean and inspect. 2 2 2 2

Lighting equipment 9 Inspect. 2 2 2 2 2

5FK-9-16-03 3/13/03 8:39 AM Page 5

8-5

NOTE:

8Recommended brake fluid: DOT 4 8Brake fluid replacement: 9 When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally

check the brake fluid level and add the fluid as required. 9 On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two

years. 9 Replace the brake hoses every four years, or if cracked or damaged.

w Indicates a potential hazard that could result in serious injury or death.

5FK-9-16-03 3/13/03 8:39 AM Page 6

8-6

EBU01098

Transmission oil Transmission oil measurement 1. Place the machine on a level surface. 2. Warm up the engine for several minutes,

and then stop it. 3. Remove the oil filler cap and wipe off the

dipstick with a clean rag. Insert the dip- stick in the filler hole without screwing it in.

1. Dipstick 2. Maximum level mark 3. Minimum level mark

NOTE: Wait a few minutes until the oil level settles before checking.

4. Remove the dipstick and inspect the oil level.

5. The oil level should be between the maxi- mum and minimum marks. If the level is low, add oil to raise it to the proper level.

6. Install the oil filler cap.

Transmission oil replacement 1. Place the machine on a level surface. 2. Warm up the engine for several minutes

and then stop it. 3. Place a container under the engine to col-

lect the used oil. 4. Remove the oil filler cap and drain bolt to

drain the oil.

q

w e

5FK-9-16-03 3/13/03 8:39 AM Page 7

1. Drain bolt

5. Install the drain bolt, and then tighten it to the specified torque.

6. Fill the engine with oil and install the oil filler cap.

cC 8 In order to prevent clutch slippage

(since the engine oil also lubricates the clutch), do not mix any chemical addi- tives. Do not use oils with a diesel specification of CD or oils of a higher quality than specified. In addition, do not use oils labeled ENERGY CON- SERVING II or higher.

8 Make sure that no foreign material enters the crankcase.

q

Tightening torque: Drain bolt:

20 Nm (2.0 m0kgf, 14 ft0lbf)

Recommended oil: See page 10-2. Oil quantity:

Total amount: 1.7 L (1.5 Imp qt, 1.8 US qt)

Periodic oil change: 1.5 L (1.3 Imp qt, 1.6 US qt)

8-7

5FK-9-16-03 3/13/03 8:39 AM Page 8

8-8

7. Start the engine and warm up for a few minutes. While warming up, check for oil leakage. If oil leakage is found, stop the engine immediately, and check for the cause.

8. Check the oil level.

EBU01080

Cooling system 1. Check the coolant level in the coolant

reservoir when the engine is cold as the coolant level will vary with engine temper- ature. The coolant level should be between the maximum and minimum marks.

1. Maximum level mark 2. Minimum level mark

2. If the level is low, remove the seat. (See page 4-12 for seat removal and installa- tion procedures.)

q

w

5FK-9-16-03 3/13/03 8:39 AM Page 9

3. Open the coolant reservoir cover.

1. Coolant reservoir cover 2. Coolant reservoir cap

4. Remove the coolant reservoir cap, and then add coolant or distilled water to raise it to the specified level.

5. Install the coolant reservoir cap.

6. Close the coolant reservoir cover. 7. Install the seat. cC Hard water or salt water is harmful to the engine. You may use soft water if you cant get distilled water.

NOTE: 8 If water is added, have a Yamaha dealer

check the antifreeze content of the coolant as soon as possible.

8 If your ATV overheats, see page 8-48 for details.

w

q

Coolant reservoir capacity: 0.28 L (0.25 Imp qt, 0.30 US qt)

8-9

5FK-9-16-03 3/13/03 8:39 AM Page 10

8-10

EBU00765

To change the coolant

1. Put the ATV on a level place. 2. Remove the radiator cover bolts, and then

remove the radiator cover.

1. Radiator cover 2. Radiator cover bolt (3)

3. Place a container under the engine and remove the coolant drain bolts.

1. Drain bolt (2)

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POTENTIAL HAZARD

Removing the radiator cap when the engine and radiator are still hot.

WHAT CAN HAPPEN

You could be burned by hot fluid and steam blown out under pressure.

HOW TO AVOID THE HAZARD

Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap.

qWARNING

5FK-9-16-03 3/13/03 8:39 AM Page 11

4. Remove the radiator cap.

1. Radiator cap

5. Remove the coolant reservoir cap.

1. Coolant reservoir cap

6. Disconnect the hose on the coolant reser- voir side and drain the coolant from the coolant reservoir.

1. Coolant reservoir hose 2. Coolant reservoir

7. After draining the coolant, thoroughly flush the cooling system with clean tap water.

8. Replace the coolant drain bolt washers if they are damaged, and then tighten the coolant drain bolts to the specified torque.

8-11

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5FK-9-16-03 3/13/03 8:39 AM Page 12

9. Install the coolant reservoir hose. 10. Pour the recommended coolant into the

radiator until it is full.

cC Hard water or salt water is harmful to the engine. You may use soft water if you cant get distilled water.

11. Install the radiator cap. 12. Run the engine several minutes. Stop the

engine, and then check the coolant level in the radiator. If it is low, add more coolant until it reaches the top of the radi- ator.

13. Fill the coolant reservoir with coolant up to the maximum level.

14. Install the coolant reservoir cap and check for coolant leakage.

NOTE: If any leakage is found, ask a Yamaha dealer to inspect the cooling system.

15. Install the radiator cover by installing the bolts.

8-12

Recommended antifreeze: High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines.

Antifreeze and water mixing ratio: 1:1

Total amount: 1.5 L (1.3 Imp qt, 1.6 US qt)

Coolant reservoir capacity: 0.28 L (0.25 Imp qt, 0.30 US qt)

Tightening torque Coolant drain bolt:

10 Nm (1.0 m0kgf, 7 ft0lbf)

5FK-9-16-03 3/13/03 8:39 AM Page 13

8-13

EBU00287

Spark plug inspection The spark plugs are important engine compo- nents and are easy to inspect. The condition of the spark plugs can indicate the condition of the engine. Normally, all spark plugs from the same engine should have the same color on the white porce- lain insulator around the center electrode. The ideal color at this point is a medium to light tan color for a machine that is being ridden normal- ly. If one spark plug shows a distinctly different color, there could be something wrong with the engine. Do not attempt to diagnose such problems your- self. Instead, take the machine to a Yamaha deal- er. You should periodically remove and inspect the spark plugs because heat and deposits will cause any spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug.

Before installing a spark plug, measure the electrode gap with a feeler gauge and adjust to specification.

a. Spark plug gap

Standard spark plug: BR8ES (NGK)

Spark plug gap: 0.70.8 mm (0.0280.031 in)

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5FK-9-16-03 3/13/03 8:39 AM Page 14

When installing a spark plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads and tighten to the specified torque.

EBU00288

Air filter cleaning

NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case.

1. Remove the seat. 2. Remove the air filter case cover.

1. Check hose

1. Air filter case cover

3. Remove the air filter element, and sepa- rate it from the guide.

8-14

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1

Tightening torque: Spark plug:

20 Nm (2.0 m0kgf, 14 ft0lbf)

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8-15

1. Air filter element 2. Element guide

4. Wash the element gently but thoroughly in solvent.

5. Squeeze the excess solvent out of the fil- ter and let it dry.

cC Do not twist the filter element when squeezing it.

6. Inspect the element. If damaged, replace it.

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POTENTIAL HAZARD

Using low flash point solvents or gaso- line to clean the air filter element.

WHAT CAN HAPPEN

Low flash point solvents or gasoline can catch fire or explode.

HOW TO AVOID THE HAZARD

Use parts cleaning solvent to clean the air filter element.

qWARNING

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8-16

7. Apply Yamaha foam air filter oil or other quality foam air filter oil to the element. If foam air filter oil is not available, motor oil may be used.

NOTE: The element should be wet but not dripping.

8. Reinstall the element to the element guide.

9. Reinstall the element assembly and parts removed for access.

NOTE: The air filter element should be cleaned every 2040 hours. It should be cleaned and lubri- cated more often if the machine is operated in extremely dusty areas. Each time filter ele- ment maintenance is performed, check the air inlet to the filter case for obstructions. Check the air cleaner rubber joint to the carburetor and manifold fittings for an airtight seal. Tighten all fittings securely to avoid the possi- bility of unfiltered air entering the engine.

cC Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid engine wear and possible engine damage. Additionally, operation without the filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating.

5FK-9-16-03 3/13/03 8:39 AM Page 17

8-17

EBU13610

Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the screws.

2. Remove the tailpipe by pulling it out of the muffler.

3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe.

4. Make sure the gasket is properly posi- tioned, then insert the tailpipe into the muffler and align the screw holes.

5. Install the screws and tighten them.

1. Screw ( 3)

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1. Tailpipe 2. Spark arrester 3. Gasket

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8-18

POTENTIAL HAZARD

Improper cleaning of the spark arrester. Hot exhaust system

WHAT CAN HAPPEN

Could injure the eyes. Could cause burns. Could cause carbon monoxide poison- ing, possibly leading to death. Could start a fire.

HOW TO AVOID THE HAZARD

When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components. Do not start the engine when cleaning the exhaust system.

qWARNING

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EBU00299

Carburetor settings In extremely cold weather, it is necessary to change the carburetor settings to maintain optimum engine performance and to prevent engine damage.

8-19

POTENTIAL HAZARD

Improperly servicing or adjusting the carburetors.

WHAT CAN HAPPEN

The carburetors could malfunction. This could cause improper operation with the possibility of an accident. The carburetors could leak fuel, which would be a fire hazard.

HOW TO AVOID THE HAZARD

Carburetor adjustments should only be performed by a Yamaha dealer. Do not

qWARNING

attempt to perform these procedures unless you have mechanical knowledge and the necessary tools. Do not perform these procedures while the engine is hot. Place a rag under each carburetor to catch any fuel. Wipe up any spilled fuel completely. After servicing the carburetors, always check throttle operation before operat- ing the ATV to make sure it is working correctly.

Standard settings

Main jet #200

Jet needle clip position 3rd groove

Pilot air screw 2.0 turns out

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8-20

Carburetor setting chart

q 1st groove

2nd

3rd (Standard)

4th

5th

Jet needle clip position

1. Main jet number

Altitude 01,500 m (5,000 ft) Above 1,500 m (5,000 ft)

Temperature Main jet Jet needle Pilot air screw Main jet Jet needle Pilot air screw Above 0C #200 3rd groove 2.0 turns out #190 3rd groove 2 1/2 turns out(32F)

+5C

15C #220 3rd groove 1 1/2 turns out #200 3rd groove 2.0 turns out (41F) (5F) 10C

30C #240 4th groove 1 1/2 turns out #220 3rd groove 1 1/2 turns out

(14F) (22F)

5FK-9-16-03 3/13/03 8:39 AM Page 21

Changing the carburetor settings Disassembly 1. Turn the fuel cock to the "OFF" position. 2. Turn out the drain screw of each carbure-

tor and drain the fuel. 3. Remove the seat. 4. Remove the radiator cover and side

cover.

5. Disconnect the fuel hoses. 6. Remove the fuel tank.

7. Remove the air filter case cover.

1. Air filter case cover

2

1

1

1. Radiator cover 2. Side cover

8-21

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8-22

8. Remove the securing plate of each carbu- retor.

1. Carburetor cap securing plate

9. Loosen the joint screws of each carbure- tor.

10. Remove each carburetor cap. 11. Remove the throttle cables from the throt-

tle valves and then remove the holder.

1. Throttle cable 2. Throttle valve 3. Holder

1

1

2 3

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8-23

12. Remove the carburetors and then remove the float chambers.

1. Float chamber

13. Remove the floats and needle valves.

1. Float 2. Needle valve 3. Main jet

14. Change the main jets and the jet needle clip positions. (See page 8-20.)

NOTE: Optional main jets can be obtained at a Yamaha dealer.

1

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8-24

Assembly 1. Reassemble the needle valves, floats and

float chambers. 2. Install the carburetors. 3. Reassemble the throttle valves. 4. Install the carburetor caps and tighten

them securely to the specified torque.

5. Install the securing plates. Match one of the projections on the carburetor cap with one of the indents on the securing plate.

1. Securing plate 2. Projection 3. Slot

cC If the securing plate does not match a pro- jection, tighten the carburetor cap until they align. Do not loosen.

6. Tighten the securing plate screw to the specified torque.

7. Tighten the joint screws of each carbure- tor.

1

2

3

Carburetor cap tightening torque: 4 Nm (0.4 m0kgf, 2.9 ft0lbf)

Tightening torque: 3.5 Nm (0.35 m0kgf, 2.5 ft0lbf)

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8-25

Throttle cable adjustment After the jet needle clip positions are changed, throttle cable adjustment may be necessary. 1. Move the throttle lever a few times. 2. Push the throttle lever forward until it

stops and hold it in this position. 3. Check through the window of each carbu-

retor to see if the punch mark on the throt- tle valve is at the specified position.

a. Specified position

4. If not, loosen the locknuts and turn the adjusters until proper position is obtained.

1. Locknut (2) 2. Adjuster (2)

5. Move the throttle lever a few times and recheck the position.

6. Install the fuel tank, side cover, radiator cover and air filter case cover.

7. Reconnect the fuel hoses. 8. Install the seat.

01mm (00.04 in)

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EBU03021

Idle speed adjustment

NOTE: A diagnostic tachometer must be used for this procedure.

NOTE: The throttle cables and carburetor synchro- nization must be set properly before adjusting the idle speed.

1. Adjust the pilot air screws. 8 Turn in both pilot air screws until they

lightly seat. 8 Turn out both pilot air screws to specifi-

cation. (Refer to the Carburetor set- tings section.)

1. Pilot air screw

2. Remove the seat. 3. Start the engine and warm it up for a few

minutes at approximately 1,000 to 2,000 r/min.

8-26

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4. Connect the tachometer and set the idle to the specified idling speed by turning the idle adjust screws. Turn the adjusting screws in direction a to increase the engine speed, and in direction b to decrease the engine speed.

1. Idle speed adjust screw (2)

cC 8 Idle speed adjust screws were preset

at the factory. When adjusting idle speed, turn the right and left idle speed adjust screws the same amount, or carburetor synchronization will be incorrect.

8 The pilot air screws and idle speed adjust screws are separate adjust- ments but they must be adjusted at the same time to achieve optimum engine performance.

8-27

1

b a ab

Specified idle speed: 1,4501,550 r/min

5FK-9-16-03 3/13/03 8:39 AM Page 28

EBU00307

Throttle lever adjustment

NOTE: Adjust the engine idling speed before adjust- ing the throttle lever free play.

1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle

lever free play is 46 mm (0.160.24 in). 3. Tighten the locknut.

1. Adjusting bolt 2. Locknut a. Free play

8-28

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EBU00309

Front and rear brake pad inspection Each brake pad is provided with a wear indi- cator. The indicators allow checking of brake pad wear without disassembling the brake. Apply the brake and inspect the wear indica- tors. If they are ALMOST in contact with the disc plate, ask a Yamaha dealer to replace the pads.

1. Wear indicator a. Wear limit 1.0 mm (0.039 in)

8-29

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1

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a

Front

Rear

1. Wear indicator a. Wear limit 1.0 mm (0.039 in)

5FK-9-16-03 3/13/03 8:39 AM Page 30

8-30

EBU13040

Brake fluid level check Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indi- cate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Observe these precautions: 8 When checking the brake fluid level, make

sure the top of the brake fluid reservoir is level.

8 Use only the designated quality brake fluid, otherwise, the rubber seals may deterio- rate, causing leakage and poor brake per- formance.

1. Minimum level mark LOWER

1. Minimum level mark LOWER

LOWERq

LOWER q

Front

Rear

Recommended brake fluid: DOT 4

5FK-9-16-03 3/13/03 8:39 AM Page 31

8 Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemi- cal reaction and lead to poor brake perfor- mance.

8 Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

8 Brake fluid may deteriorate painted sur- faces or plastic parts. Always clean up spilled fluid immediately.

8 Have a Yamaha dealer check the cause if the brake fluid level goes down.

EEBU11860

Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. 8 Replace the oil seals every two years. 8 Replace the brake hoses every four years.

8-31

5FK-9-16-03 3/13/03 8:39 AM Page 32

8-32

EBU11870

Front brake lever free play The front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a Yamaha dealer check the brake sys- tem.

POTENTIAL HAZARD

Operating with improperly serviced or adjusted brakes.

WHAT CAN HAPPEN

You could lose braking ability, which could lead to an accident.

HOW TO AVOID THE HAZARD

After servicing: 8 Make sure the brakes operate smooth-

ly and that the free play is correct. 8 Make sure the brakes do not drag. 8 Make sure the brakes are not spongy.

All air must be bled from the brake system.

Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer.

qWARNING

a

a. Free play

5FK-9-16-03 3/13/03 8:39 AM Page 33

8-33

EBU11910

Brake pedal height adjustment The top of the brake pedal should be posi- tioned 10 mm (0.39 in) below the top of the footrest. If not, have a Yamaha dealer adjust it.

a. 10 mm (0.39 in)

POTENTIAL HAZARD

Operating with improperly serviced or adjusted brakes.

WHAT CAN HAPPEN

You could lose braking ability, which could lead to an accident.

HOW TO AVOID THE HAZARD

After servicing: 8 Make sure the brakes operate smooth-

ly and that the brake pedal position is correct.

8 Make sure the brakes do not drag. 8 Make sure the brakes are not spongy.

All air must be bled from the brake system.

Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer.

qWARNING

a

5FK-9-16-03 3/13/03 8:39 AM Page 34

EBU11930

Parking brake adjustment Parking brake adjustment may be required if the parking brake does not hold properly. The cable length A should be adjusted to 4650mm (1.811.97in).

A. Cable length

1. Fully loosen the locknut and the adjusting bolt at the clutch lever.

1. Locknut 2. Adjusting bolt

2. Loosen the locknut and the adjusting bolt at the rear brake caliper.

3. Turn the adjusting bolt at the clutch lever in direction a to increase the cable length or in direction b to decrease the cable length.

NOTE: If the cable cannot be adjusted to specification, consult a Yamaha dealer

4. Tighten the locknut at the clutch lever.

8-34

A

a

b

1 2

Tightening torque: Locknut:

16 Nm (1.6 m0kgf, 11 ft0lbf)

5FK-9-16-03 3/13/03 8:39 AM Page 35

5. Screw in the adjusting bolt at the rear brake caliper by hand until it feels tight, then screw it out 1/8 turn. Tighten the locknut to the specified torque.

1. Adjusting bolt 2. Locknut

cC When tightening the locknut, hold the adjusting bolt with a wrench so that the adjusting bolt does not turn together with the locknut.

POTENTIAL HAZARD

Operating with improperly adjusted brakes.

WHAT CAN HAPPEN

The brakes could malfunction, causing reduced braking performance. This could increase the chance of a collision or accident.

HOW TO AVOID THE HAZARD

After adjusting the parking brake, block the rear of the machine off the ground and spin the rear wheels. Check to make sure there is no brake drag. If brake drag is noticed, perform the adjustment again.

qWARNING

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8-35

5FK-9-16-03 3/13/03 8:39 AM Page 36

EBU00833

Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and brake lever, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows.

1. Rear brake light switch 2. Adjusting nut

Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction a. To make the brake light come on later, turn the adjusting nut in direction b.

EBU00539

Clutch adjustment The clutch lever free play should be 510 mm (0.200.39 in). If the free play is incorrect, adjust as follows.

1. Loosen the locknut. 2. Turn the adjusting bolt so that clutch lever

free play is 510 mm (0.200.39 in). 3. Tighten the locknut.

8-36

1 2

a b

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a

1. Locknut 2. Adjusting bolt a. Free play

5FK-9-16-03 3/13/03 8:39 AM Page 37

EBU11440

Drive chain slack check NOTE: Move the ATV back and forth and find the tight- est position of the drive chain. Check and/or adjust the chain slack while it is in this tightest position.

To check the drive chain slack, all tires must be touching the ground and there should be no weight on it. Check the drive chain slack at the position shown in the illustration Normal slack is approxi- mately 1520 mm (0.590.79 in). If the slack exceeds 20 mm (0.79 in), adjust it to specification.

EBU00351

Drive chain slack adjustment 1. Loosen the rear wheel hub bolts.

1. Upper wheel hub bolt (2) 2. Lower wheel hub bolt (2)

2. Loosen the adjuster locknuts on each side. To tighten the chain, turn the chain adjuster clockwise. To loosen the chain, turn the adjuster counterclockwise and push the wheel forward. Turn each adjuster exactly the same amount to maintain correct axle alignment. There are marks on each side of the swingarm and on each chain adjuster. Use them to check for proper alignment.

a

a. 1520 mm (0.590.79 in) 8-37

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3. After adjusting, be sure to tighten the lock- nuts and the wheel hub bolts.

EBU00805

Lubricating the drive chain The drive chain must be cleaned and lubricat- ed at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.

cC The drive chain must be lubricated after washing the ATV or riding in the rain.

1. Clean the drive chain with kerosene and a small soft brush.

cC To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate solvents.

Upper wheel hub bolt: 120 Nm (12.0 m0kgf, 85 ft0lbf)

Lower wheel hub bolt: 60 Nm (6.0 m0kgf, 43 ft0lbf)

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1. Locknut 2. Adjuster 3. Alignment marks

8-38

5FK-9-16-03 3/13/03 8:39 AM Page 39

1. O-rings

2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a

special O-ring chain lubricant.

cC Do not use engine oil or any other lubri- cants for the drive chain, as they may con- tain substances that could damage the O- rings.

EBU00356

Cable inspection and lubrication

Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them.

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8-39

POTENTIAL HAZARD

Damaged control cables.

WHAT CAN HAPPEN

Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury.

HOW TO AVOID THE HAZARD

Inspect cables frequently. Replace dam- aged cables.

qWARNING

5FK-9-16-03 3/13/03 8:39 AM Page 40

EBU00737

Brake and shift pedal/brake and clutch lever lubrication Lubricate the pivoting parts of each lever and pedal.

EBU01018

Front upper and lower arm pivot lubrica- tion Lubricate the upper and lower arm pivots.

8-40

Recommended lubricant: Lithium-soap-based grease (all-purpose grease)

Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil

Recommended lubricant: Lithium-soap-based grease

5FK-9-16-03 3/13/03 8:39 AM Page 41

8-41

EBU00987

Rear arm pivot lubrication Lubricate the rear arm pivots.

Recommended lubricant: Lithium-soap-based grease

5FK-9-16-03 3/13/03 8:39 AM Page 42

8-42

EBU01112

Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable

stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel.

EBU00871

Wheel installation When install ing the wheel, reverse the removal procedure. Tighten the wheel nuts to the specif ied torques.

Front

Rear

Tightening torque: Wheel nut:

Front: 45 Nm (4.5 m0kgf, 32 ft0lbf) Rear : 45 Nm (4.5 m0kgf, 32 ft0lbf)

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8-43

EBU01139

Replacing a headlight bulb If a headlight bulb burns out, replace the bulb as follows. 1. Remove the screw holding the headlight

unit assembly to the headlight body.

1. Screw

2. Remove the bulb holder cover.

3. Turn the bulb holder counterclockwise to remove the defective bulb.

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POTENTIAL HAZARD

A headlight bulb is hot when it is on and immediately after it is turned off.

WHAT CAN HAPPEN

You can be burned, or a fire could start if the bulb touches something flammable.

HOW TO AVOID THE HAZARD

Wait for the bulb to cool before touching or removing it.

qWARNING

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8-44

4. Put a new headlight bulb into position and secure it in place with the bulb holder.

5. Install the bulb holder cover. cC Make sure the bulb holder cover is secure- ly fitted over the bulb holder and seated against the reflector.

6. Install the headlight unit assembly. 7. Adjust the headlight beam if necessary.

EBU01089

Headlight beam adjustment

cC It is advisable to have a Yamaha dealer make this adjustment.

To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b.

1. Adjusting screw

a b

1

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1. Bulb holder cover 2. Bulb holder 3. Reflector

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8-45

EBU00861

Tail/brake light bulb replacement 1. Remove the bulb holder (together with the

bulb) by turning it counterclockwise.

1. Bulb holder

2. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise.

1. Bulb holder 2. Bulb

3. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise.

4. Install the bulb holder (together with the bulb).

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EBU00412

Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any prob- lem in the fuel, compression, or ignition sys- tems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer.

The skilled technicians at a Yamaha dealer- ship have the tools, experience, and know- how to properly service your machine. Use only genuine Yamaha parts on your machine. Imitation parts may look like Yamaha parts, but they are often inferior. Consequently, they have a shorter service life and can lead to expensive repair bills.

8-46

POTENTIAL HAZARD

Checking the fuel system while smoking or near an open flame.

WHAT CAN HAPPEN

Fuel can ignite or explode, causing severe injury or property damage.

HOW TO AVOID THE HAZARD

Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or fur- naces.

qWARNING

5FK-9-16-03 3/13/03 8:39 AM Page 47

EBU00440

Troubleshooting chart Starting problems or poor engine performance

8-47

Check fuel flow

1. Fuel

Check if there is fuel in the fuel tank

2. Compression

Kick the kick starter to see if there is compression

3. Ignition

Remove plugs and check electrodes

Wet Wipe clean with dry cloth

Dry Attach plug cap and ground to chassis

Kick the kick starter strongly Spark weak

Spark good Ignition system normal

No spark

Ask a Yamaha dealer to inspect

Adjust plug gap or replace plug(s)

There is compresson Compression normal

Ask a Yamaha dealer to inspectNo compression

There is fuel Turn the fuel cock to OFF

Remove the fuel pipe No fuel Fuel cock clogged

Clean fuel cock

Some fuel Turn the fuel cock to RES Restart engine

No fuel Supply fuel

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8-48

Engine overheating

Wait until the engine has cooled.

Check the coolant level in the reservoir tank and/or radiator.

Level is OK.

Level is low, check the cooling system for leakage.

No leakage.

Leakage. Ask a Yamaha dealer to inspect and repair the cooling system.

Add coolant. (See NOTE.)

Restart the engine. If the engine overheats again, ask a Yamaha dealer to inspect and/or repair the cooling system.

NOTE: If it is difficult to get recommended coolant, tap water can be temporarily used, provided that it is changed to the recommended coolant as soon as possible.

5FK-9-16-03 3/13/03 8:39 AM Page 49

8-49

POTENTIAL HAZARD

Removing the radiator cap when the engine and radiator are still hot.

WHAT CAN HAPPEN

You could be burned by hot fluid and steam blown out under pressure.

HOW TO AVOID THE HAZARD

Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap.

qWARNING

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EBU00414

No spark Throttle OverRide System (T.O.R.S.) is incor- porated in the ignition circuit, and if the sys- tem should fail, the spark plug will not spark.

8-50

POTENTIAL HAZARD

Testing for an ignition system problem by disconnecting the Throttle OverRide System (T.O.R.S.).

WHAT CAN HAPPEN

With T.O.R.S. disconnected, the engine will not stop if the throttle does not close properly. This could cause loss of control and an accident. You could be burned if you touch the hot exhaust pipe while disconnecting the wire coupler.

qWARNING

HOW TO AVOID THE HAZARD

Have the system checked by a Yamaha dealer. Before bypassing T.O.R.S., be sure the throttle closes properly when the throt- tle lever is released. If the machine must be ridden, ride as slowly as possible. Do not touch the exhaust pipe when dis- connecting the wire coupler.

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8-51

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EDU00415

CLEANING AND STORAGE

A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine:

a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may be used.

b. Make sure the spark plugs and all filler caps are properly installed.

2. If the engine case is excessively greasy, apply degreaser with a paint brush. Do not apply degreaser to the chain, sprock- ets or wheel axles.

3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure to do the job.

cC Excessive water pressure may cause water seepage and deterioration of wheel bear- ings, brakes, transmission seals and elec- trical devices. Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail- able in coin-operated car washers.

4. Once the majority of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bottle brush is handy for hard-to-get-at places.

5. Rinse the machine off immediately with clean water and dry all surfaces with a chamois, clean towel or soft absorbent cloth.

6. Dry the chain and lubricate it to prevent rust.

9-1

9

5FK-9-16-03 3/13/03 8:39 AM Page 53

7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.

8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish.

When finished, start the engine and let it idle for several minutes.

9-2

POTENTIAL HAZARD

Operation with wet brakes after wash- ing.

WHAT CAN HAPPEN

Wet brakes may have reduced stopping ability, increasing the chance of an acci- dent.

HOW TO AVOID THE HAZARD

Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings.

qWARNING

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EBU00529

B. STORAGE Long term storage (60 days or more) of your machine will require some preventive proce- dures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Drain the fuel tank, fuel lines and carbure-

tor float bowls. 2. Remove the spark plugs, pour about one

tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug holes and rein- stall the spark plugs. Ground the spark plug wires and turn the engine over sever- al times to coat the cylinder walls with oil.

3. Clean the drive chain thoroughly and lubricate it. (See page 8-38 for details.) Reinstall the chain or store it in a plastic bag tied to frame for safekeeping.

4. Lubricate all control cables.

5. Block up the frame to raise all wheels off the ground.

6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering.

7. If storing in a humid or salt-air atmos- phere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat cover.

NOTE: Make any necessary repairs before storing the machine.

9-3

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10-1

EBU00428

SPECIFICATIONS

Model YFZ350

Dimension: Overall length 1,855 mm (73.0 in) Overall width 1,100 mm (43.3 in) Overall height 1,080 mm (42.5 in) Seat height 800 mm (31.5 in) Wheel base 1,280 mm (50.4 in) Minimum ground clearance 135 mm (5.31 in) Minimum turning radius: 3,600 mm (141.7 in)

Basic weight: With oil and full fuel tank 187 kg (412 lb)

Engine: Type Liquid cooled, 2-stroke Cylinder arrangement Forward inclined parallel 2-cylinder Displacement 347 cm3

Bore Stroke 64 54 mm (2.52 2.13 in) Compression ratio 6.5 : 1 Starting system Kick starter Lubrication system Premix

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10-2

Model YFZ350

Engine oil (2-cycle): Type Yamalube R, Castrol R30, A545, A747 Mixing ratio See page 5-6.

Transmission oil: Type Yamalube 4 (10W30) or SAE 10W30 Recommended engine oil classification: API Service SE, SF, SG type or higher

cC In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of CD or oils of a higher quality than specified. In addition, do not use oils labeled ENER- GY CONSERVING II or higher.

Capacity Periodic oil change 1.5 L (1.3 Imp qt, 1.6 US qt) Total amount 1.7 L (1.5 Imp qt, 1.8 US qt)

Radiator capacity: (Including all routes) 1.5 L (1.3 Imp qt, 1.6 US qt)

Air filter: Wet type element

10

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10-3

Model YFZ350

Fuel: Type Premium unleaded fuel, Premix Tank capacity 12.0 L (2.6 Imp gal, 3.2 US gal) Reserve amount 2.5 L (0.5 Imp gal, 0.7 US gal)

Carburetor: Type/quantity VM26SS/2 Manufacturer MIKUNI

Spark plug: Type/manufacturer BR8ES/NGK Spark plug gap 0.70.8 mm (0.0280.031 in)

Clutch type: Wet, multiple-disc

Transmission: Primary reduction system Helical gear Primary reduction ratio 66/23 (2.869) Secondary reduction system Chain drive Secondary reduction ratio 41/14 (2.929) Transmission type Constant mesh 6-speed Operation Left foot operation

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10-4

Model YFZ350

Gear ratio 1st 32/13 (2.461) 2nd 29/16 (1.812) 3rd 27/18 (1.500) 4th 25/20 (1.250) 5th 23/22 (1.045) 6th 21/24 (0.875)

Chassis: Frame type Steel tube frame Caster angle 9 Trail 40 mm (1.57 in)

Tire: Type Tubeless Size front AT21 7 - 10

rear AT20 10 - 9

Brake: Front brake type Dual disc brake

operation Right hand operation Rear brake type Single disc brake

operation Right foot operation

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10-5

Model YFZ350

Suspension: Front suspension Double wishbone Rear suspension Swingarm (link suspension)

Shock absorber: Front shock absorber Coil spring/Oil damper Rear shock absorber Coil spring/Gas-Oil damper

Wheel travel: Front wheel travel 230 mm (9.1 in) Rear wheel travel 220 mm (8.7 in)

Electrical: Ignition system C.D.I. Generator system C.D.I. magneto

Headlight Type: Krypton bulb

Bulb voltage, wattage quantity: Headlight 12V, 30W/30W 2 Tail/brake light 12V, 5W/21W 1

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11-1

EBU13640

NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inopera- tive by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

"AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW."

These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust system Muffler Exhaust pipe Silencer

Air cleaner case Air cleaner element Intake duct

Intake system

11

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12-1

EBU13651

MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

MAINTENACE INTERVAL

1 Month

3 Months

6 Months

12 Months

18 Months

24 Months

30 Months 36 Months

42 Months

48 Months

54 Months

60 Months

DATE OF

SERVICE

SERVICING DEALER NAME AND ADDRESS

REMARKS

5FK-9-16-03 3/13/03 8:39 AM Page 62

12

12-2

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13-1

EBU00433

Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha ATV purchased from an authorized Yamaha ATV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, sub- ject to certain stated limitations.

THE PERIOD OF WARRANTY for al l YFZ model Yamaha ATVs shall be ninety (90) days from the date of purchase.

DURING THE PERIOD OF WARRANTY any authorized Yamaha ATV dealer will, free of charge, repair or replace, at Yamahas option, any part adjudged defec- tive by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the products warranty period. All parts replaced under warranty become property of Yamaha Motor Corp. U.S.A.

GENERAL EXCLUSIONS from this warranty shall include any failures caused by: a. Competition or racing use. b. Installation of parts or accessories that are not

qualitatively equivalent to genuine Yamaha parts. c. Abnormal strain, neglect, or abuse. d. Lack of proper maintenance. e. Accident or collision damage. f. Modification to original parts. g. Damage due to improper transportation.

SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance; such as spark plugs, oil, oil filter, air filter, and brake shoes.

THE CUSTOMERS RESPONSIBILITY under this war- ranty shall be to: 1. Operate and maintain the ATV as specified in the

appropriate owners manual; 2. Give notice to an authorized Yamaha ATV dealer

of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealers place of business.

WARRANTY TRANSFER: To transfer the warranty from the original purchaser to any subsequent pur- chaser(s), i t is imperative that the machine be inspected and registered for warranty by an autho- rized Yamaha ATV dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. An inspection and registration fee will be charged for this service.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

YAMAHA MOTOR CORPORATION, U.S.A. P.O. Box 6555

Cypress, California 90630

YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY

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13-2

13

WARRANTY QUESTIONS AND ANSWERS

Q. What costs are my responsibility during the warranty period? A. The customers responsibility includes all costs of normal maintenance services,

non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes.

Q. What are some examples of abnormal strain, neglect, or abuse? A. These terms are general and overlap each other in areas. Specific examples include:

Running the machine out of oil, sustained high-rpm, full-throttle, operating the machine with a broken or damaged part which causes another part to fail, damage or failure due to improper or careless transportation and or tie down. If you have any specific questions on operation or maintenance, please contact your dealer for advice.

Q. Does the warranty cover incidental costs such as towing or transportation due to a failure?

A. No. The warranty is limited to repair of the machine itself.

Q. May I perform any or all of the recommended maintenance shown in the Owners Manual instead of having the dealer do them?

A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owners and Service Manual. We do recommend, however, that i tems requiring special tools or equipment be done by Yamaha ATV dealer.

Q. Will the warranty be void or cancelled if I do not operate or maintain my new ATV exactly as specified in the Owners Manual?

A. No. The warranty on a new ATV cannot be voided or cancelled. However, if a particular failure is caused by operation or maintenance other than as shown in the Owners Manual, that failure may not be covered under warranty.

Q. What responsibility does my dealer have under this warranty? A. Each Yamaha ATV dealer is expected to:

1. Completely set up every new machine before sale. 2. Explain the operation, maintenance, and warranty requirements to your satis-

faction at the time of sale, and upon your request at any later date. 3. Each Yamaha ATV dealer is held responsible for his setup, service and war-

ranty repair work.

Q. Is the warranty transferable to second owners? A. Yes. The reminder of the existing warranty can be transferred upon request. The

unit has to be inspected and re-registered by an authorized Yamaha ATV dealer for the policy to remain effective.

CUSTOMER SERVICE

If your machine requires warranty service, you must take it to any authorized Yamaha ATV dealer within the continental United States. Be sure to bring your warranty registration card or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write:

YAMAHA MOTOR CORPORATION U.S.A. CUSTOMER RELATIONS DEPARTMENT

P.O. Box 6555 Cypress, California 90630

When contacting Yamaha Motor Corporation, U.S.A. dont forget to include any important information such as names, addresses, model, V.I.N. (frame number), dates, and receipts.

CHANGE OF ADDRESS

The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related defect and recall. This list is compiled from the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase.

If you should move after you have purchased your new ATV, please advise us of your new address by sending a postcard listing your ATV model name, V.I.N. (frame number), dealer number (or dealer s name) as it is shown on your warranty card, your name and new mailing address. Mail to:

YAMAHA MOTOR CORPORATION, U.S.A. P.O. Box 6555

Cypress, California 90630 Attention: Warranty Department

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

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EBU00436

w Indicates a potential hazard that could result in serious injury or death.

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EBU00437

PROTECT YOUR INVESTMENT

5FK-9-16-03 3/13/03 8:39 AM Page 68

YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN

2003032.01 !

This ATV should not be ridden by anyone under 16 years of age.

OWNERS MANUAL

5FK-28199-16

YFZ350S

READ THIS MANUAL CAREFULLY! It contains important safety information.

LIT-11626-17-04 (E)

w

Improper ATV use can result in SEVERE INJURY or DEATH.

qWARNING

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR

NEVER USE ON PUBLIC

ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

NEVER operate: 9 without proper training or instruction. 9 at speeds too fast for your skills or the

conditions. 9 on public roads - a collision can occur with

another vehicle. 9 with a passenger - passengers affect

balance and steering and increase risk of losing control.

ALWAYS: 9 use proper riding techniques to avoid

vehicle overturns on hills and rough terrain and in turns.

9 avoid paved surfaces - pavement may seriously affect handling and control.

EBU00438

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Manualsnet FAQs

If you want to find out how the YFZ350S Yamaha works, you can view and download the Yamaha YFZ350S Banshee 2004 Owner's Manual on the Manualsnet website.

Yes, we have the Owner's Manual for Yamaha YFZ350S as well as other Yamaha manuals. All you need to do is to use our search bar and find the user manual that you are looking for.

The Owner's Manual should include all the details that are needed to use a Yamaha YFZ350S. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

The best way to navigate the Yamaha YFZ350S Banshee 2004 Owner's Manual is by checking the Table of Contents at the top of the page where available. This allows you to navigate a manual by jumping to the section you are looking for.

This Yamaha YFZ350S Banshee 2004 Owner's Manual consists of sections like Table of Contents, to name a few. For easier navigation, use the Table of Contents in the upper left corner.

You can download Yamaha YFZ350S Banshee 2004 Owner's Manual free of charge simply by clicking the “download” button in the upper right corner of any manuals page. This feature allows you to download any manual in a couple of seconds and is generally in PDF format. You can also save a manual for later by adding it to your saved documents in the user profile.

To be able to print Yamaha YFZ350S Banshee 2004 Owner's Manual, simply download the document to your computer. Once downloaded, open the PDF file and print the Yamaha YFZ350S Banshee 2004 Owner's Manual as you would any other document. This can usually be achieved by clicking on “File” and then “Print” from the menu bar.